Method for manufacturing busbar and manufacturing busbar through the same

ABSTRACT

According to an embodiment of the present disclosure, provided is a method for manufacturing a bus bar in which a frame including a sensing part and a body part connected to the sensing part is prepared, the frame is inserted into and fixed to an injection molding mold, and an enhanced part enhancing the strength at a position where fatigue is concentrated by an enhancing injection material injected into the injection molding mold is formed in the frame.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 16/500,406, filed Oct. 3, 2019 (issued as U.S. Pat. No. 10,894,346,on Jan. 19, 2021), which is a national phase entry of InternationalApplication No. PCT/KR2018/003987, filed on Apr. 4, 2018, which claimsthe benefit of and priority to Korean Patent Application Nos.10-2017-0043568, filed on Apr. 4, 2017; 10-2017-0063539, filed on May23, 2017; and 10-2017-0078748, filed on Jun. 21, 2017, the content ofwhich are herein incorporated by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to a method for manufacturing a bus barand the bus bar manufactured by the same.

BACKGROUND ART

In general, as a method for manufacturing a bus bar, there are a methodfor manufacturing a bus bar by manufacturing a body part and a sensingpart separately and bonding them to each other and a method formanufacturing the bus bar by integrating them. Among them, the methodfor manufacturing the bus bar by manufacturing the sensing part and thebody part separately and bonding them by welding or the likeadditionally requires a manufacturing process of bonding, and causes anincrease in the manufacturing process and the cost due to degradation ofdurability of a bonded part and the degradation of durability of thebonded part. On the other hand, in order to solve this problem, themethod for manufacturing the bus bar by integrating them may omit thebonding process, and may not occur the breakage of the degradation ofdurability at the bonded part. However, relaxation and contraction mayoccur due to an impact applied to the bus bar, and the relaxation andthe contraction may cause a short circuit between the sensing part andthe body part.

RELATED ART DOCUMENT Patent Document

[Patent Document 1] Korean Patent Laid-Open Publication No.10-2014-0146232 (Dec. 24, 2014)

DISCLOSURE Technical Problem

In order to solve a problem due to a short circuit of a connection partcaused by relaxation and contraction of a body part and a sensing partby the conventional bus bar for an electric vehicle using an integratedbus bar of the body part and the sensing part, an object of anembodiment of the present disclosure is to provide a method formanufacturing an integrated bus bar of a body part and a sensing partand then manufacturing it so that the body part and the sensing part ofthe bus bar are positioned in the thickness of an injection-moldedproduct by performing a primary or primary and secondary insertinjection molding for the integrated bus bar, and a method formanufacturing a bus bar that secures durability of the bus bar byinjection-molding only the sensing part.

In order to solve a problem due to a short circuit of a connection partcaused by relaxation and contraction of a body part and a sensing partby the conventional bus bar for an electric vehicle using an integratedbus bar of the body part and the sensing part, another object of anembodiment of the present disclosure is to provide a method formanufacturing an integrated bus bar of a body part and a sensing partand then manufacturing it so that the body part and the sensing part ofthe bus bar are positioned in the thickness of an injection-moldedproduct by performing a primary or primary and secondary insertinjection molding for the integrated bus bar, and a bus bar that securesdurability of the bus bar by injection-molding only the sensing part.

In order to solve a problem that may cause degradation of the pricecompetitiveness and a quality problem due to the difficulty inconfirming the presence or absence of the bonding due to manymanufacturing processes in the process of manufacturing a body part anda sensing part with a heterogeneous material, respectively to bond themthrough ultrasonic, laser, or the like, still another object of anembodiment of the present disclosure is to provide a method formanufacturing an integrated bus bar of a body part and a sensing partand then manufacturing it so that the body part and the sensing part ofthe bus bar are positioned in the thickness of an injection-moldedproduct by performing a primary or primary and secondary insertinjection molding for the integrated bus bar, and a method formanufacturing a bus bar that secures durability of the bus bar byinjection-molding only the sensing part.

In order to solve a problem that may cause degradation of the pricecompetitiveness and a quality problem due to the difficulty inconfirming the presence or absence of the bonding due to manymanufacturing processes in the process of manufacturing a body part anda sensing part with a heterogeneous material, respectively to bond themthrough ultrasonic, laser, or the like, still another object of anembodiment of the present disclosure is to provide a method formanufacturing an integrated bus bar of a body part and a sensing partand then manufacturing it so that the body part and the sensing part ofthe bus bar are positioned in the thickness of an injection-moldedproduct by performing a primary or primary and secondary insertinjection molding for the integrated bus bar, and a bus bar that securesdurability of the bus bar by injection-molding only the sensing part.

Technical Solution

According to an embodiment of the present disclosure, provided is amethod for manufacturing a bus bar in which a frame including a sensingpart and a body part connected to the sensing part is prepared, theframe is inserted into and fixed to an injection molding mold, and anenhanced part is formed in the frame in order to improve the degree ofone or more of the strength and the insulation at one or more positionsof a position where fatigue is concentrated and a position capable ofelectrical conduction by an enhancing injection material injected intothe injection molding mold.

Further, the insertion and the fixing may be performed by a protrusionin the injection molding mold, and the protrusion may be introduced intothe injection molding mold by the supply pressure of the enhancinginjection material.

Further, the enhancing injection material may be injected into theinjection molding mold once to form the enhanced part in the frame.

Further, the fatigue may occur in a direction in which the frame isrepeatedly bent.

Further, the fatigue may occur at one or more positions of the body partand the sensing part.

Further, the frame may further include a connection part connectingbetween the sensing part and the body part.

Further, the fatigue may occur at one or more positions of the bodypart, the sensing part, and the connection part.

The enhancing injection material may include a primary enhancinginjection material and a secondary enhancing injection material injectedsequentially, and one surface of the frame may be enhanced through aprimary injection molding by injecting the primary enhancing injectionmaterial therein, and the other surface of the frame may be enhancedthrough a secondary injection molding by injecting the secondaryenhancing injection material therein.

Further, the fatigue may occur in a direction in which the frame isrepeatedly bent.

Further, the fatigue may occur at one or more positions of the body partand the sensing part.

Further, the frame may further include a connection part connectingbetween the sensing part and the body part.

Further, the fatigue may occur at one or more positions of the bodypart, the sensing part, and the connection part.

Further, a nonferrous metal may be aluminum or copper.

Further, the frame may further include a connection part connectingbetween the sensing part and the body part, and one or more of theprimary injection molding and the secondary injection molding may beperformed on the connection part.

Further, the frame may further include a connection part connectingbetween the sensing part and the body part, and the connection part maybe prepared to have elasticity.

Further, elasticity may be provided by a curved part prepared on theconnection part.

Further, the connection part may be surface-treated by one or more amongnickel, tin, gold, silver, and zinc.

Further, the body part may include a through hole to enhance a heatdissipation property and a low resistance property.

Further, the through hole may be a rectangular or circular hole.

Further, the frame may be adhered to an upper mold by a protrusionformed in the injection molding mold so that an insert position is fixedduring the primary injection molding and the secondary injectionmolding.

Further, the frame may include an irregularity part enhancing theadhesion with the primary enhancing injection material and the secondaryenhancing injection material.

Further, the irregularity part may include at least one among a hole, aspike, and a drawing, and may be formed on one or more contact surfacesof the frame and the primary enhancing injection material or thesecondary enhancing injection material.

Further, the primary enhancing injection material and the secondaryenhancing injection material may be different materials from each other.

Further, one or more of the primary enhancing injection material and thesecondary enhancing injection material may include resin.

Further, at least partial portion in which a wire may be coupled to thebody part may be blocked from being injected by the primary enhancinginjection material and the secondary enhancing injection material,respectively, during the primary injection molding and the secondaryinjection molding.

Further, the frame may include a carrier configured to fix the frame tothe injection molding mold during the primary injection molding and thesecondary injection molding.

Further, the frame may be manufactured in a state where the frame and aguide have been connected, and the guide and the frame may be connectedby a notch to separate the frame and the guide with respect to the notchafter the secondary injection molding.

Further, the sensing part may be plated by one among gold, silver,nickel, tin, and zinc.

Provided is a bus bar including a sensing part, a body part connected tothe sensing part, and an enhanced part enhancing one or more of thestrength and the insulation of the body part, and the enhanced part isformed at one side of the body part, and the enhanced part is made ofone or more materials.

Further, the bus bar may further include a connection part connectingbetween the sensing part and the body part.

Provided is a bus bar including a sensing part, a connection part havingone side coupled to the sensing part, a body part coupled to the otherside of the connection part, and an enhanced part formed at one side inthe body part and the connection part, and enhancing one or more of thestrength and the insulation at one or more positions of the connectionpart and the body part.

Further, the enhanced part may include a primary enhancing injectionmaterial and a secondary enhancing injection material, and one or moreof the primary enhancing injection material and the secondary enhancinginjection material may be resin.

Provided is a bus bar including a sensing part, a connection part havingone side coupled to the sensing part, a body part coupled to the otherside of the connection part, and an enhanced part enhancing one or moreof the strength and the insulation in the connection part and the bodypart, and the body part is prepared in plural and stacked on each other,and the enhanced part is formed on a portion of an exposed surface in astate where the body part has been stacked on each other.

Advantageous Effects

An embodiment of the present disclosure may provide the bus bar, whichmay secure the thickness and tensile strength of the body and secure theelastic force of the sensing part, thereby preventing the short circuitof the connection part due to relaxation and contraction.

An embodiment of the present disclosure may provide a method formanufacturing the bus bar, which may not separate the manufacturingprocess, thereby preventing degradation of the price competitiveness.

DESCRIPTION OF DRAWINGS

FIG. 1 is a flowchart illustrating a process of manufacturing a bus baraccording to an embodiment of the present disclosure.

FIG. 2 is a perspective diagram of a frame according to an embodiment ofthe present disclosure.

FIG. 3A and FIG. 3B are perspective diagrams of a bus bar according toembodiments of the present disclosure.

FIG. 4A is a perspective diagram of a frame according to anotherembodiment of the present disclosure, and FIG. 4B is a diagram of aprotrusion formed in a mold according to an embodiment of the presentdisclosure.

FIGS. 5A, 5B, and 5C are diagrams illustrating a shape of a bus baraccording to other embodiments of the present disclosure.

FIG. 6 is a diagram illustrating a shape of a stacked bus bar accordingto another embodiment of the present disclosure.

FIGS. 7A to 7C are diagrams illustrating the injection of an enhancinginjection material according to embodiments of the present disclosure.

BEST MODE

Hereinafter, a specific embodiment of the present disclosure will bedescribed with reference to the accompanying drawings. However, this ismerely for illustrative and the present disclosure is not limitedthereto.

In the following description of the present disclosure, if it isdetermined that a specific description of the known technology relatedto the present disclosure unnecessarily obscures the gist of the presentdisclosure, a detailed description thereof will be omitted. Further,terms to be described later are terms defined considering the functionin the present disclosure, which may be changed according to the intent,custom, or the like of a user or an operator. Accordingly, itsdefinition should be made based on the contents throughout the presentspecification.

The technical spirit of the present disclosure is determined by theclaims, and the following embodiment is merely a means for efficientlyexplaining the technical spirit of the present disclosure to thoseskilled in the art to which the present disclosure pertains.

Further, hereinafter, a method for enhancing a frame (10 in FIG. 2) anda bus bar (20 in FIG. 3A) manufactured by the method will be describedlater. Here, the enhancement may be a purpose of enhancing the strengthagainst an external impact to be applied to the frame (10 in FIG. 2) anda purpose of adding, maintaining, and enhancing the insulation from theoutside. For example, if the manufactured bus bar (20 in FIG. 3A) isconnected with a battery of a vehicle, the bus bar 20 may be affected bythe vibration generated during driving of the vehicle. At this time, thebending, or the like may be affected by the vibration and pressuredelivered from a surrounding structure, and here, it may be said to be akind of enhancing process of enhancing the resistance of the bending.Accordingly, the most vulnerable point due to the bending may be formedas an enhanced part in the manufacturing process in order to enhance thestrength from the bending that causes fatigue. A position of theenhanced part may be one or more positions of the body parts (420, 520,620 in FIG. 5A, FIG. 5B, and FIG. 5C) and the sensing parts (410, 510,610 in FIG. 5A, FIG. 5B, and FIG. 5C), and may be formed on a connectionpart (112 in FIG. 2) if the frame (10 in FIG. 2) includes the connectionpart (112 in FIG. 2). For example, the enhanced part may also be formedon the connection part that is formed to be relatively narrow in widthand vulnerable to the bending. Of course, a curved part (113 in FIG. 2)may be formed on the connection part (112 in FIG. 2) and may also bestructurally formed to have the elasticity at the point where thebending is applied.

Further, for the purpose of adding, maintaining, and enhancing theinsulation from the outside, it is possible to serve as a coating. Thatis, it is possible to conceal an area exposed from the outside, therebypreventing an electrical accident such as a short that may be caused bythe inevitable contact with the surrounding structure. It is possible toprevent the electrical accident caused by the contact with the moistureas well as the surrounding structure in advance. Accordingly, it ispossible to inject a material capable of suppressing the electricalconductivity during the injection without injecting an enhancinginjection material that may serve as a conductor after the curing duringthe injection. For example, it is possible to inject the enhancinginjection material containing a resin material during the injection,thereby adding, maintaining, and enhancing the insulation.

Hereinafter, an embodiment in which an enhancing injection process isperformed in plural times and an embodiment in which an enhancinginjection process is performed once in order to form the enhanced partwill be described later. An embodiment in which primary and secondaryinjection moldings are performed will be described with reference toFIGS. 1 to 6, and a process of forming the enhanced part through aone-time injection molding process will be described with reference toFIG. 7. Further, when the description is made with reference to FIG. 7,different points therebetween will be mainly described in comparisonwith the contents described with reference to FIGS. 1 to 6.

FIG. 1 is a flowchart illustrating a process of manufacturing the busbar (20 in FIG. 2) according to an embodiment of the present disclosure.

Referring to FIG. 1, the bus bar (20 in FIG. 2) may be manufactured inthe order of manufacturing a frame (operation S1), injecting a primaryenhancing injection material (operation S2), injecting a secondaryenhancing injection material (operation S3), and detaching (operationS4). Specifically, the manufacturing the frame (operation S1) maymanufacture the frame (10 in FIG. 2) including a sensing part (110 inFIG. 2) and a body part (120 in FIG. 2). The frame (10 in FIG. 2)manufactured by a method such as a press may be manufactured as the busbar (20 in FIG. 3A) while being coupled through the enhancing injectionmaterial and the injection. The frame (10 in FIG. 2) may be manufacturedby including shapes of a curved part 113, a sensing hole 111 a, and thelike in the sensing part (110 in FIG. 2) and shapes of a curved part123, a hollow hole 121 a, and the like in the body part 120. That is, ashape that is the base of the bus bar (20 in FIG. 3A) may be prepared.Here, the sensing part 110 and the body part 120 may be integrallyformed, and do not include a separate bonding process. Accordingly, itis possible to prevent degradation of the durability due to the couplingstructure.

That is, it is possible to enhance the mechanical performance by beingmanufactured integrally. Here, the mechanical performance may meanperformance of maintaining a coupling force against the vibration, orthe like, performance capable of resisting against the breakage that mayoccur from an external force, or the like. Such performance may beadvantageous because of having a higher resistance than that of the busbar manufactured by the coupling between two members against thevibration of the vehicle, or the like if the bus bar (20 in FIG. 3A) ofan embodiment of the present disclosure is included for example, in acomponent of the vehicle, or the like. Of course, as described above, itis also possible to expect the enhancement in the insulation. Since theeffect that may be expected from the enhanced part is optional, theenhancing injection material may be determined as a metal material whenthe rigidity is prioritized to the insulation by those skilled in theart, and determined as a material such as a resin material when theinsulation is prioritized to the rigidity. Accordingly, a material ofthe enhancing injection material is optional, and it is possible toadjust the specific gravity of the insulation and the rigidity by fusinga plurality of materials. Furthermore, it is also possible to providethe elasticity to the enhanced part.

Further, the frame manufactured in the manufacturing the frame(operation S1) may be, for example, 5 mm. The 5 mm is an example of thethickness corresponding to 50% of the thickness of the bus barmanufactured without undergoing the process of being enhanced throughthe injection, and the present disclosure is not limited to 5 mm.Hereinafter, a process of manufacturing a bus bar will be described bytaking the frame manufactured to the thickness of 5 mm as an example.

The frame (10 in FIG. 2) manufactured through the manufacturing theframe (operation S1) may enhance a portion having a weak durability,that is, a portion where a stress may be concentrated by an externalforce. For example, an enhancing injection material may be injected forthe purpose of enhancing the frame (10 in FIG. 2). Accordingly, in orderto inject it by injecting the enhancing injection material, the frame(10 in FIG. 2) may be disposed in a primary injection molding mold andthe injecting the primary enhancing injection material (operation S2)may be performed. The primary enhancing injection material may beinjected, for example, into one surface of the frame (10 in FIG. 2).Here, one surface of the frame (10 in FIG. 2) may be the bottom surfaceof the frame (10 in FIG. 2), and may be a portion of the bottom surfaceor the entire bottom surface.

Further, thereafter, the mold may be rearranged to perform the injectingthe secondary enhancing injection material (operation S3). If theenhancing injection material has been injected into the bottom surfacein the injecting the primary enhancing injection material (operationS2), only an upper mold may be rearranged and the secondary enhancinginjection material may be injected therein. In this case, the secondaryenhancing injection material may be injected (operation S3) into theother surface of the frame (10 in FIG. 2). Here, the other surface maybe the upper surface of the frame (10 in FIG. 2), and may be a portionof the upper surface or the entire upper surface.

However, in the injecting the primary enhancing injection material(operation S2) and the injecting the secondary enhancing injectionmaterial (operation S3), the sensing part (110 in FIG. 2), as a terminalcapable of the electrical conduction, may be blocked from the injectionof the enhancing injection material. Accordingly, the sensing part (110in FIG. 2) may be exposed even after being manufactured as the bus bar(20 in FIG. 3A). Here, the frame (10 in FIG. 2) may be made of anonferrous metal, for example, aluminum or copper. Further, theenhancing injection materials injected primarily and secondarily maycontain at least resin. Accordingly, if the enhancing injection materialis not blocked for the sensing part (110 in FIG. 2), the electricalconduction through the sensing part (110 in FIG. 2) may be impossible,such that the enhancing injection material may be blocked. Furthermore,the sensing part (110 in FIG. 2) may be plated with one material ofgold, silver, nickel, tin, and zinc.

Meanwhile, in the mold disposed for injecting the primary enhancinginjection material and the secondary enhancing injection material, theframe (10 in FIG. 2) has been fixed in the mold and then the enhancinginjection material may be injected (operations S2, S3), and a fixingmeans may be formed to prevent the frame (10 in FIG. 2) from being movedin the mold by the injected enhancing injection material.

One or more of a hole, a spike, and a drawing may be formed in theframe, formed on the contact surfaces where the primary enhancinginjection material, the secondary enhancing injection material, and theframe (10 in FIG. 2) may contact each other, and formed on one or morecontact surfaces among the contact surfaces, thereby enhancing theadhesion between the frame (10 in FIG. 2) and one or more of the primaryenhancing injection material and the secondary enhancing injectionmaterial.

Meanwhile, the injected enhancing injection material may be fixed to theframe (10 in FIG. 2) to enhance a low durability portion of the frame(10 in FIG. 2). Further, this enhancing injection material may beinjected for the purpose of enhancing the durability, but may also beinjected to form a heat dissipation surface. For example, if one surfaceof the body part 120 has been disposed in the mold to be injected intoonly some areas when being injected by the enhancing injection material,an area where the enhancing injection material is not supplied may beexposed to the outside. Since the exposed surface is exposed even afterthe bus bar (20 in FIG. 3A) has been manufactured, it may be a surfacewhere the heat generated during the flow of the current may bedissipated. For example, the heat dissipating surface is one surface ofthe body part 120, and as the exposed area is wider, the heatdissipation is better.

Subsequently, the detaching the mold (operation S4) may separate it froma guide (330 in FIG. 4) in the case of manufacturing by furtherincluding the guide (330 in FIG. 4) in the frame (10 in FIG. 2) in theinjecting the enhancing injection materials (operations S2, S3). Thiswill be described later in detail with reference to FIG. 4.

FIG. 2 is a perspective diagram of the frame 10 according to anembodiment of the present disclosure.

Referring to FIG. 2, the frame 10 may include the sensing part 110 andthe body part 120. Here, the sensing part 110 may have the sensing hole111 a for connecting with the terminal formed therein, and may beconnected with the body part 120 through the connection part 112according to the spacing distance with the terminal. That is, thesensing part 110 is connected with one side of the connection part 112and the other side of the connection part 112 is connected with the bodypart 120, such that the sensing part 110 and the body part 120 may beelectrically connected. In this embodiment, the curved part 113 may beformed on the connection part 112 to structurally provide the elasticityto the frame 10. As described above, if the curved part 113 is includedin a component of the vehicle, the curved part 113 may be a structure inwhich the vibration may be generated by the vehicle during driving andthe resistance against the above may be enhanced. The curved part 113may also be formed in the body part 120. The curved part 123 of the bodypart 120 may also be the same reason as described above.

As described above, the thickness of the frame 10 may be 0.5 mm. Thisthickness may be made thicker by forming enhanced parts (213 a, 220 a inFIG. 3A and FIG. 3B), and accordingly, may be determined considering thethickness of the enhanced part when manufacturing the frame 10. That is,if the enhanced parts (213 a, 220 a in FIG. 3A and FIG. 3B) are notformed or are formed only on one side thereof, the thickness of theframe 10 may be determined to be 1 mm to 1.5 mm during the manufacturingthereof.

Meanwhile, the body part 120 may have a valley 121 and a ridge 122 bythe curved part 123. A hollow hole 121 a may be formed in a portion ofthe valley 121, the ridge 122, and the curved part 123. The illustratedexample is an example in which the hollow hole 121 a has been formed inthe valley 121, but may be formed even in the ridge, and it is possibleto expect the effects such as the heat dissipation and electrical lowresistance property through the hollow hole 121 a.

In particular, regarding the heat dissipation, the exposed area in theair of the body part 120 may be increased by the curved part 123,thereby further increasing the heat dissipation effect. Of course, thiseffect may also correspond to the curved part 113 formed on theconnection part 112. Further, heat may be dissipated through the exposedsurface if the surface exposed to the outside is formed even after aprimary enhancing injection material (222 a in FIG. 3B) and a secondaryenhancing injection material (223 a in FIG. 3B) have been positioned inthe frame 10.

Referring to FIGS. 3A and 3B, as the bus bar 20 manufactured bysupplying the enhancing injection materials 222 a, 223 a to the frame 10in FIG. 2, the bus bar 20 may further include enhanced parts 213 a, 220a in the frame 10. By forming the enhanced parts 213 a, 220 a, thethickness of the bus bar 20 may be increased overall or locally. Thisexample is an example in which the enhancing injection materials 222 a,223 a have been injected into the curved part 213 and a portion of thebody part 220, and the current passing cross-sectional areas of the bodypart 220 and the curved part 213 are increased by the enhancinginjection materials 222 a, 223 a, thereby reducing the electricalresistance to enhance the electrical conductivity and to enhance thedurability by the vibration.

As described above, since the enhanced parts 213 a, 221 a may beselectively formed by a primary injection molding and a secondaryinjection molding, for example, the enhancing injection materials 222 a,223 a may be injected into the curved part 213 to form the enhanced part213 a, and the enhanced part 220 a may be formed on one end of the bodypart 120, which may be connected with a separate member. As describedabove, since the enhanced parts 213 a, 220 a may be selectively formedby the primary injection molding and the secondary injection molding,the enhanced part may be formed even in any portion not described inthis example as many as possible.

Meanwhile, the enhanced parts 213 a, 220 a may be enhanced twice on thebottom surface and the top surface of the frame 10. If the primaryenhancing injection material 222 a is injected into the bottom surfaceof the body part 120 of the frame 10 to be coupled with the frame 10,the secondary enhancing injection material 223 a is injected into thetop surface of the body part 120 to be coupled with the frame 10. Asdescribed above, the thickness of the bus bar at this time may be 1 mmto 1.5 mm. Further, the primary enhancing injection material 222 a andthe secondary enhancing injection material 223 a may be differentmaterials from each other, and at least one material may be resin.

FIG. 4 is a diagram illustrating the frame 30 and a partial structure ofthe mold 1 according to another embodiment of the present disclosure;and FIG. 4A is a perspective diagram of the frame 30 according toanother embodiment of the present disclosure and FIG. 4B is aperspective diagram of a protrusion 2 formed in the mold according to anembodiment of the present disclosure.

Referring to FIG. 4A, the frame 30 may further include the guide 330 inthe frame 10 described above. The guide 330 is a structure for fixingthe frame 30 not to be moved when the enhancing injection material issupplied in the mold 1 during the primary injection molding and thesecondary injection molding, and may be positioned in the mold 1 duringthe primary injection molding and the secondary injection molding. Forexample, the guide 330 may allow a portion of the frame 30 positionedinside the mold 1 to be fixed without being moved.

The frame 30 having a structure integrally formed with the guide 330 maybe connected by a notch 330 a in the mold. The notch 330 a may separatethe guide 330 from the frame 30 by a method such as the cutting afterthe secondary injection molding. That is, the notch 330 a may allow theframe 30 to be fixed without being moved in the mold 1, and when thesecondary injection molding is completed, the connection area ispreferably formed to be small so that the guide 330 is easily separated.

Further, a pinhole 331 may be formed in the guide 330 for the fixing.The guide 331 may be fixed to fix the frame 30 and the pinhole 331 maybe coupled with and fixed to a pin formed in the mold. Accordingly, twopinholes 331 may be formed. Of course, it is a structure for the fixing,which is limited to a circular case, and in the case of a prismatic holesuch as a square, one or more holes may also be formed.

Referring to FIG. 4B, as another fixing method of the frame 10 in themold 1, the protrusion 2 is formed in the mold 1, and a groovecorresponding to the protrusion 2 may be formed in the frame 10. Theprotrusion 2 is a structure for pressing the frame 10, and although theprotrusion 2 is not formed to correspond to the groove, the protrusion 2may contact the surface of the frame 10 to support the frame 10. As oneembodiment, the protrusion 2 may be protruded from the mold 1, and maybe disposed with the mold 1 with an elastic body 3 interposedtherebetween. That is, in order to fix the frame 10, the protrusion 2may press the frame 10 by the elastic body 3 in a direction protrudingfrom the mold 1.

FIGS. 5A, 5B, and 5C are diagrams illustrating bus bars 40, 50, 60according to other embodiments of the present disclosure. Specifically,FIG. 5A is a diagram illustrating the bus bar 40 of a “⊏” shape, FIG. 5Bis a diagram illustrating the bus bar 50 of a “¬” shape, and FIG. 5C isa diagram illustrating the bus bar 60 of a “Z” shape. This example isintended to disclose various examples in terms of shapes of the bus bars40, 50, 60.

Referring to FIG. 6, as an example in which the bus bars 40, 50, 60 havesensing parts 410, 510, 610 positioned on both ends thereof,respectively, and have body parts 420, 520, 620 positioned between therespective sensing parts 410, 510, 610, the bending of the body parts420, 520, 620 may be formed variously.

Furthermore, here, the bus bars 20, 40, 50, 60 manufactured by theinsert injection may be made of a nonferrous metal, and for example, thenonferrous metal may be aluminum, copper, or the like. Further, themanufactured bus bars 20, 40, 50, 60 may be formed so that thethicknesses of the body part 200 and the connection part 100 becomedifferent by the enhanced parts (213 a, 221 a in FIG. 3A) through theenhancement by the enhancing injection materials 222 a, 223 a. Theelasticity may be determined by the difference.

Further, the bus bars 20, 40, 50, 60, in which the injecting the primaryenhancing injection material (operation S2) and the injecting thesecondary enhancing injection material (operation S3) have beenperformed in the frame 10 by the enhancing injection materials 222 a,223 a, may have the sensing parts 210, 410, 510, 610 surface-treated bynickel, tin, or the like. In addition to the surface treatment, thesensing parts 210, 410, 510, 610 may be configured by forming a platinglayer including at least any one of nickel, gold, copper, and tin.

Further, in order to enhance the adhesion by the enhancing injectionmaterials 222 a, 223 a injected during the primary injection molding andthe secondary injection molding, the frames 10, 30 may have anirregularity part formed on the outer surface contacting the frame 1.The irregularity part is non-uniform and rough, includes a protrusion oruneven shape, and includes one or more of a hole, a spike, and adrawing. The enhancing injection materials 222 a, 223 a may be injectedinto the irregularity part side to further increase the coupling forcebetween the frames 10, 30 and the enhancing injection materials 222 a,223 a after the curing.

Further, the body parts 120, 320, which may be heat-generated by theflow of the current, have the injection of the enhancing injectionmaterials 222 a, 223 a during the secondary injection moldingasymmetrically performed on one surface and the other surface thereof,such that the enhanced part for the enhancement may be formed only onone surface side of the body parts 120, 320. Accordingly, the othersurface side of the body parts 120, 320 where the enhanced part is notformed may be exposed to the outside, which may be advantageous todissipate the heat due to the heat generation.

Further, the enhanced part formed by the enhancing injection materialmay also be positioned at a position except for the sensing parts 110,210, 310, 410, 510, 610. The cross-sectional area and the outer surfacearea of the flow direction of the current of the portion thickened bythe enhancing injection material may be increased in the bus bars 20,40, 50, 60, thereby enhancing the electrical conductivity and the heatdissipation property. Further, the sensing parts 110, 210, 310, 410,510, 610 may be plated, and the plating may include at least one ofgold, silver, nickel, zinc, tin, or the like and the electricalconduction property may be further enhanced by the plating.

FIG. 6 is a diagram illustrating a shape of a stacked bus bar 70according to another embodiment of the present disclosure. FIG. 6exemplarily illustrates a case where two frames have been stacked, but acase where three or more frames are stacked may also be applied to thefollowing description.

Referring to FIG. 6, it may be an embodiment in which the insertinjection is performed in a state where a plurality of frames have beenstacked. For example, as a form of stacking a plurality of frames, bodyparts (42; 421 a, 421 b) and respective connection parts 412 a, 412 b ofeach frame may be stacked and the stacked frame may be inserted into themold and injection-molded.

Here, the primary enhancing injection material 222 a and the secondaryenhancing injection material 223 a to be injected during the injectionmolding may be injected into the lower surface and the upper surface ofthe stacked frame, respectively. In this example in which two frameshave been stacked, the primary enhancing injection material 222 a may besupplied to the body parts (42; 421 b) positioned at the lower sidethereof, and the secondary enhancing injection material 223 a may besupplied to the body parts (42; 421 a) positioned at the upper sidethereof. Here, the enhancing injection materials 222 a, 223 a may beinjected into a portion of the exposed areas of the stacked frame or theentire exposed area thereof.

When the enhancing injection materials 222 a, 223 a are injected intothe portion, for example, the enhancing injection materials 222 a, 223 amay be supplied to a planar portion. The planar portion may includevalleys 421 a, 421 b, a ridge 422 a, and the like except for the curvedparts 423 a, 413 a, 413 b. A portion into which the enhancing injectionmaterials 222 a, 223 a are injected may be performed for the purpose ofenhancing the durability, or the like, as in the above-describedembodiment.

Furthermore, the area into which the enhancing injection materials 222a, 223 a are injected may further include the side surface of thestacked frame. The coupling between the respective frames may be made byinjecting it by stacking a plurality of frames and then injecting theenhancing injection materials 222 a, 223 a into the surface includingthe side surface thereof. In addition to the coupling by the enhancinginjection materials 222 a, 223 a, the coupling state contacting eachother by a welding including a laser welding and an adhesive agentbetween the respective frames may be maintained.

Further, if the respective frames are coupled to each other by theenhancing injection materials 222 a, 223 a, the inflow of the enhancinginjection materials 222 a, 223 a may be blocked between the respectiveframes. Accordingly, when being inserted into the mold, the stackedframe may coupled by being pressed to each other by a pressing meanssuch as the bending so that the enhancing injection materials 222 a, 223a are not injected between the respective frames.

Although the above-described embodiment has described an example inwhich the enhancing injection material is injected twice primarily andsecondarily to enhance the frames 10, 30, an embodiment to be describedbelow is an example of enhancing the enhanced part formed in the frames10, 30 by injecting the enhancing injection material once.

Hereinafter, the same applicable points as those of the embodiment inwhich the enhancing injection material is injected in plural times(primary and secondary) as described above are omitted and differentpoints will be mainly described later.

FIG. 7A to 7C are diagrams illustrating the injection of the enhancinginjection material according to embodiments of the present disclosure,and referring to FIGS. 7A to 7C, the enhancing injection material may beinjected after the frames 10, 30 have been mounted in the mold 1. Here,the mounting of the frames 10, 30 in the mold 1 means the mountinghaving a fixing force of the degree that the frames 10, 30 may maintaintheir positions in the mold 1 against the pressure generated when theenhancing injection material is injected.

For example, the mounting may be performed by one or more protrusions 2formed in the mold 1. Specifically, the protrusion 2 may be coupled bythe mold 1 and the elastic body 3. Accordingly, the protrusion 2 mayreceive the elasticity from the elastic body 3 in a direction ofsupporting the frames 10, 30 to press, mount, and fix the frames 10, 30with a predetermined force.

Referring to FIG. 7A, the frames 10, 30 supported and fixed by theprotrusion 2 are introduced into a cavity 4 in the mold 1 by theenhancing injection material, and the introduced enhancing injectionmaterial may be provided up to a position adjacent to the protrusion 2.Since the protrusion 2 may be a pin or cylinder shape, the enhancinginjection material may be provided up to the periphery of the protrusion2. If the projection 2 is pressed by the pressure of the enhancinginjection material as in FIG. 7B, the protrusion 2 may be introducedinto the mold 1. For the introduction, the protrusion 2 may have aninclined surface formed on the end portion in the pressing direction.The inclined surface is formed at an angle except for a directionparallel or perpendicular to a direction (D) of injecting the enhancinginjection material, and may be formed in a direction of reducing thecross-sectional area as the protrusion 2 extends in the pressingdirection. Accordingly, the enhancing injection material presses theinclined surface to introduce the protrusion 2 into the mold 1, and thepositions of the frames 10, 30 may be maintained by the enhancinginjection material.

If the enhancing injection material is injected by the above-describedprocess and the enhancing injection material is cured, the frame mayhave the enhanced parts 213 a, 221 a formed at the position where theenhancing injection material has been injected. Although the enhancinginjection material has been injected into the upper and lower surfaceswith respect to the frames 10, 30 in this embodiment, the cavity 4 isformed only on one side surface according to the shape of the mold 1 toinject the enhancing injection material into the cavity 4 side.Accordingly, the position where the enhanced parts 213 a, 221 a areformed in the frames 10, 30 may be optional, and if the enhanced parts213 a, 221 a are formed on the upper surface and the lower surface ofthe frames 10, 30, they may also be manufactured by injecting theprimary and secondary enhancing injection materials, and may also bemanufactured by injecting the enhancing injection material once.

As described above, although the representative embodiments of thepresent disclosure have been described in detail, it will be understoodby those skilled in the art to which the present disclosure pertainsthat various modifications to the above-described embodiments may bemade without departing from the scope of the present disclosure.Accordingly, the scope of the present disclosure should not be limitedto and defined as the embodiment described, and should be defined by notonly the appended claims set forth below but also equivalents of theclaims.

The invention claimed is:
 1. A method for manufacturing a bus bar,wherein a frame comprising a sensing part and a body part connected tothe sensing part is prepared, wherein all or part for forming thefollowing reinforcement part in the frame is inserted into and fixed toan injection molding mold by a protrusion in the injection molding mold,and wherein an enhanced part is formed in one or more of the body partand the sensing part's connection part of the frame in order to improvethe degree of one or more of the strength and the insulation at one ormore positions of a position where fatigue is concentrated and aposition capable of electrical conduction by an enhancing injectionmaterial injected into the injection molding mold, and wherein athickness of the enhanced part is formed to be adjustable, the enhancinginjection material is injected at a time or sequentially injected atleast two times or more.
 2. The method for manufacturing the bus bar ofclaim 1, wherein the protrusion is introduced into the injection moldingmold by the supply pressure of the enhancing injection material.
 3. Themethod for manufacturing the bus bar of claim 1, wherein the fatigueoccurs in a direction in which the frame is repeatedly bent.
 4. Themethod for manufacturing the bus bar of claim 3, wherein the fatigueoccurs at one or more positions of the body part and the sensing part.5. The method for manufacturing the bus bar of claim 3, wherein theframe further comprises a connection part connecting between the sensingpart and the body part.
 6. The method for manufacturing the bus bar ofclaim 5, wherein the fatigue occurs at one or more positions of the bodypart, the sensing part, and the connection part.
 7. The method formanufacturing the bus bar of claim 1, wherein the enhancing injectionmaterial comprises a primary enhancing injection material and asecondary enhancing injection material injected sequentially, andwherein one surface of the frame is enhanced through a primary injectionmolding by injecting the primary enhancing injection material therein,and the other surface of the frame is enhanced through a secondaryinjection molding by injecting the secondary enhancing injectionmaterial therein.
 8. The method for manufacturing the bus bar of claim7, wherein the fatigue occurs in a direction in which the frame isrepeatedly bent.
 9. The method for manufacturing the bus bar of claim 8,wherein the fatigue occurs at one or more positions of the body part andthe sensing part.
 10. The method for manufacturing the bus bar of claim8, wherein the frame further comprises a connection part connectingbetween the sensing part and the body part.
 11. The method formanufacturing the bus bar of claim 10, wherein the elasticity isprovided by a curved part prepared on the connection part.
 12. Themethod for manufacturing the bus bar of claim 7, wherein the frame isformed with a groove that may be fixed by a protrusion formed in theinjection molding mold so that an insert position is fixed during theprimary injection molding and the secondary injection molding.
 13. Themethod for manufacturing the bus bar of claim 7, wherein the framecomprises an irregularity part enhancing the adhesion with the primaryenhancing injection material and the secondary enhancing injectionmaterial.
 14. The method for manufacturing the bus bar of claim 7,wherein the primary enhancing injection material and the secondaryenhancing injection material are different materials from each other.15. The method for manufacturing the bus bar of claim 7, wherein theframe is manufactured in a state where the frame and a guide have beenconnected, and wherein the guide and the frame are connected by a notchto separate the frame and the guide with respect to the notch after thesecondary injection molding.
 16. A bus bar, comprising: a sensing part;a connection part having one side coupled to the sensing part; a bodypart coupled to the other side of the connection part; an enhanced partformed at one side thereof in the body part and the connection part, andenhancing one or more of the strength and the insulation at one or morepositions in the connection part and the body part, and wherein athickness of the enhanced part is formed to be adjustable in aninjection molding mold.
 17. A bus bar, comprising: a sensing part; aconnection part having one side coupled to the sensing part; a body partcoupled to the other side of the connection part; and an enhanced partenhancing one or more of the strength and the insulation in theconnection part and the body part, wherein the body part is prepared inplural and stacked on each other, and the enhanced part is formed on aportion of an exposed surface in a state where the body part has beenstacked on each other, and wherein a thickness of the enhanced part isformed to be adjustable in an injection molding mold.